Installation Guide IQ Controller Pro

Transcription

1 Installation Guide IQ Controller Pro 651 South Main Street Middletown, CT (800) (860) Fax (860) P/N Version DEC2006

2 Note: The initial USER ID and PASSWORD are User ID: setup Password: IQ 1

3 THE IQ CONTROLLER PRO SYSTEM IS DESIGNED TO INTERFACE WITH BIOSYSTEMS GAS DETECTORS. BIOSYSTEMS GAS DETECTORS HAVE BEEN DESIGNED FOR THE DETECTION OF DEFICIENCIES OF OXYGEN, ACCUMULATIONS OF FLAMMABLE GASES AND VAPORS AND ACCUMULATIONS OF TOXIC VAPORS. IN ORDER TO ENSURE THAT THE USER IS PROPERLY WARNED OF POTENTIALLY DANGEROUS ATMOSPHERIC CONDITIONS, IT IS ESSENTIAL THAT THE INSTRUCTIONS IN THIS MANUAL AND THE OPERATIONS AND/OR REFERENCE MANUALS FOR THE GAS DETECTOR(S) BE READ, FULLY UNDERSTOOD, AND FOLLOWED. THIS MANUAL IS NOT INTENDED TO REPLACE THE OPERATIONS AND/OR REFERENCE MANUALS FOR THE GAS DETECTOR. THIS MANUAL IS ONLY DESIGNED TO AID IN THE INSTALLATION OF THE IQ CONTROLLER PRO SYSTEM AND SHOULD BE USED IN CONJUNCTION WITH THE INSTRUMENT REFERENCE OR OPERATIONS MANUAL AT ALL TIMES. Installation Guide IQ System IQ Controller Pro Part Number Version 2.10 Copyright 2006 by Biosystems LLC Middletown, Connecticut All rights reserved. No page or part of this operation manual may be reproduced in any form without written permission of the copyright owner shown above. Biosystems reserves the right to correct typographical errors. 2

4 Table of Contents Warnings and Cautions...4 A. Signal Words Overview Delivery PC Requirements Requirements Instrument-IQ Compatibility Instrument Firmware Requirements Special MultiVision Firmware Requirements Power Requirements Special Cannonball3 IQ Dock Power Requirements Operating and Storage Environments Sensor compatibility Installation Overview Database Installation on Local or Network Drive Installing the IrDA Drivers PC Port Requirements Installation Guidelines: ACTiSYS IrDA Drivers Installing the IQ Administrator Pro Program Installing the IQ Database Manager Pro Program Installing IQ Controller Pro Software Hardware Initial Installation Database Manager Pro Software Overview Launch Database Manager Pro Users Templates Using the system PhD5 and PhD Ultra Special Operating Instructions IQ Dock Status LEDs Controller Use Calibrate now Software Configuration Software Launch Gas Manager Backup Cylinders Custom Gas Mixtures Calibration Interval (Days) Fault Notification Schedule Processing Zero Purge Time Exiting the Gas Configuration screen System Changes Upgrading IQ Controller Pro Software Adding or removing an IQ Dock

5 9.3 Addition of Solenoid Blocks Cleaning the IQ System Contacting Biosystems...20 Calibration Frequency...21 Biosystems Standard Warranty Gas Detection Products...22 Warnings and Cautions A. Signal Words The following signal words, as defined by ANSI Z , are used in the IQ System Reference Manual. indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. indicates a potentially hazardous situation, which if not avoided, may result in moderate or minor injury. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. 4

6 1. Overview The IQ Controller is an automatic calibration station coupled with a data management system that is designed to interface with Biosystems Gas Detectors. The IQ Controller Pro System relies on userdefined templates to determine which functions to perform on a specific instrument. To maximize flexibility with a wide variety of Biosystems gas detectors, the IQ System allows for the programming of multiple templates. Each instrument must be assigned to a specific template. Whenever a new instrument enters the system, the Generic (No Change) template is automatically assigned to it. Section 7.3 gives a brief overview of template use in the IQ System. The key to the functionality of the IQ system lies in understanding how different forms of information enter the database. The database is typically housed locally, but may also be housed on a network, which allows multiple controllers to feed information to a single database. For more information on Network Database Installation, see section 1.9 below. IQ Controller Pro systems use a PostgreSQL Database that must be installed on the PC before the system will be functional. The PostgreSQL database can only be accessed through IQ s Database Manager Pro program. User and template information are controlled through the Database Manager Pro Program. Instrument information including sensor and calibration data is uploaded automatically when the instrument is placed in a docking station and recognized by the IQ Pro System. Note: The installation and set up instructions in this manual must be followed in the specific order stated in section 1.8 to ensure the functionality of the system. 1.1 Delivery The IQ system is delivered with the following items: IQ Controller IQ Dock(s) XTNDAccess IrDA USB Adapter Driver CD or ACTiSYS IrDA USB Adapter Drive CD (not included with PhD5 or PhD Ultra docks) IQ System installation CD (includes the IQ Controller Pro and the Database Manager Pro software). Termination Plug Gas lines for connecting the IQ Docks and the IQ Controller. Cannonball3 IQ Docks include a gas line with quick disconnect nipple for connecting the IQ Dock to the instrument. Calibration Gas Termination Tube Link Plate(s) (if more than one IQ Dock is ordered) 1.2 PC Requirements Pentium II Processor 400MHz or better or equivalent. 128MB RAM required, 256MB RAM highly recommended see note below Windows 2000/XP 30MB hard drive disk space. Note: Windows XP or Windows 2000 with Service Pack 3 is required for instruments that communicate via infrared (PhD Lite, MultiVision and Cannonball3) PC Port Requirements During the installation of the IQ System, 4 serial port drivers will be installed on your PC. These drivers must be positioned so that they occupy sequential ports numbered between 1 and 12. In the event that your PC is already using more than 8 ports, it will be necessary to either temporarily reduce the number of available ports, or reconfigure the existing ports so that the serial port drivers can occupy sequential ports numbering between 1 and 12. For more details on your PC s port settings, see section 2.1 below Requirements Enabling the IQ System s function requires configuration of the network server that interfaces with the IQ Controller as follows: 1. The mailserver s SMTP listener task must be enabled. 2. Mail relaying to the addresses listed in the Database Manager Pro must be allowed. Please contact your system administrator for further details. 1.4 Instrument-IQ Compatibility Instrument Firmware Requirements For all Biosystems gas detectors, the instrument firmware version is shown when the instrument is first turned on. 5

7 Cannonball 3: Version 3.02 or higher. MultiPro: Version 1.12 or higher. MultiVision: Version 3.28 or higher with fully enabled datalogging see section below (see Special MultiVision Firmware Requirements below). PhD5: Version 3.11 or higher (Firmware version is shown at instrument start up) PhD Lite: Version 3.21 or higher with OTP version 1.10 or higher. (Firmware version is shown at instrument start up. To access the OTP version enter the Main Menu / View / Version and press the right arrow key. If or any number less than 1.10 is shown, the instrument will need the OTP upgrade). PhD Ultra: Version 3.40 or higher Special MultiVision Firmware Requirements The MultiVision must have firmware version 3.28 or higher with fully enabled datalogging for the instrument to interface with the IQ system. To verify that your MultiVision has the datalogging option, simply turn the instrument on. If the MultiVision is equipped with a fully enabled datalogger, the datalog screen will be shown following the date screen and preceding the warning alarm levels screen. The figure at the upper right will vary with the instrument configuration settings. 1.5 Power Requirements The IQ Controller may be used with either of the following electrical power supplies. The appropriate power supply should be specified at the time of purchase VAC, 60Hz, 9A VAC, 50Hz, 4.5A In some cases, the power supply will include a voltage input selector switch. Be sure to set the switch to the appropriate voltage for your electrical supply Special Cannonball3 IQ Dock Power Requirements The NiMH version of the Cannonball3 includes the most powerful rechargeable battery pack currently offered by Biosystems, so the IQ Docking Station for the Cannonball3 requires its own power source. A power supply is included with each Cannonball3 IQ Docking Station Operating and Storage Environments The IQ Controller should only be operated in an environment with temperatures between 0 C and 40 C (32 F and 104 F) with relative humidity between 20% and 80%. The IQ Controller may be stored in an environment with temperatures between - 20 C and 60 C (-4 F and 140 F) with relative humidity between 10% and 95%. 1.7 Sensor compatibility The IQ Controller is capable of calibrating instruments containing only the following sensor types: O 2 LEL CO H 2 S Duo-Tox (CO and H 2 S) SO 2 NH 3 Note: Instruments configured with sensors other than O 2, LEL, CO, H 2 S, Duo- Tox, SO 2 and NH 3 may not be used with the IQ Controller. Span Calibration will automatically fail for all sensors in the instrument if the IQ System detects a sensor other than those listed above. Calibration gases and air are drawn in through the inlet ports that are located on the back of the IQ Controller. To ensure accurate calibration, each gas source must be correctly entered in the Calibration Gas Configuration screen and the source must be mapped to the correct gas inlet port in the software. For details on calibration gas mapping see section Installation Overview Note: Do not plug the IQ Controller into the electrical outlet until the IrDA software (Cannonball3, MultiPro, MultiVision and PhD Lite only) and the IQ Controller Pro software have been installed. In order to complete the installation of the IQ Controller, the following steps must be accomplished: 1. If the IQ Controller is to be used with an instrument that requires an IrDA interface (PhD Lite, MultiVision or Cannonball3), verify that there are 8 or less COM ports currently in use, then install the appropriate IrDA USB Adapter Driver disk. See section 2 below.

8 2. Install the PostGreSQL Database Server and the IQ Administrator Pro Program as described in the IQ Administrator Pro Reference Manual. See section 3 below. 3. Install the IQ Database Manager Pro program as described in the IQ Database Manager Pro Reference Manual. See section 4 below. 4. Install the IQ Controller Pro Software on the PC that will be used to interface with the IQ Controller and Docking Stations. See section 5 below. 5. Create a default PostgreSQL database as described in section 6 of the IQ Administrator Pro Reference Manual. 6. Assemble all hardware components. See section 6 below. Note: The IQ Controller is not designed for use in areas where high concentrations of Radio Frequency Interference (RFI) are present. 7. Launch the IQ Database Manager Pro program, set up the basic configuration of the database and then close the database. This may include entering personnel and passwords, setting up system templates and assigning instruments to templates. See section 7 below for a brief overview of the IQ Database Manager Pro Program. See the IQ Database Manager Pro reference manual for complete instructions. 8. Launch the IQ Controller Pro Software and follow the directions in section 8 to configure the IQ system for your gas detection program. At minimum, this will include entering specific calibration gas values into the software and mapping the calibration gas cylinders to the appropriate gas input ports. Note: The Generic (No Change) template is automatically assigned to any new instruments. Templates are discussed in detail in section Database Installation on Local or Network Drive The database used by the IQ System can be housed on your local hard drive or on a network drive. Network installation allows multiple users to interface with the database from different terminals at the same time. To install the database on a network drive, specify the location of the network drive during the installation of the database. 7 Although the database itself can be saved on a network drive, the IQ Controller Pro Software and the Database Manager Pro software must be installed on all PCs that will be used to interface with the IQ components. 2. Installing the IrDA Drivers For gas detectors that feature an IrDA interface (Cannonball3, MultiPro, MultiVision, PhD Lite,) it is necessary to install an IrDA Adapter Driver on your PC. Note: The installation of the IrDA drivers MUST precede the installation of the Database Manager Pro and the IQ Controller Pro Software. 2.1 PC Port Requirements If your IQ System requires an IrDA interface (Cannonball3, MultiPro, MultiVision, PhD Lite), 4 serial port drivers will be installed on your PC. The serial port drivers must be positioned so that they occupy 4 sequential communications (COM) ports numbered between 1 and 12. In the event that your PC is already using more than 8 COM ports, it will be necessary to either temporarily reduce the number of available ports, or reconfigure the existing ports so that the IrDA drivers can occupy 4 sequential ports numbering between 1 and 12. To verify the number of ports currently being used by your PC, click on Start / Settings / Control Panel / System followed by the Harware tab. Then click on Device Manager and select Ports (COM & LPT). If 4 sequential ports numbered between 1 and 12 are not available, you will need to temporarily reduce the number of ports currently being used by your PC. Contact your system administrator for details. Programs that are removed may be reinstalled following IQ installation. 2.2 Installation Guidelines: ACTiSYS IrDA Drivers. NOTE: Do not plug the IrDA transceiver in until you have installed the ACTiSYS software. Note: Screens may be slightly different depending on your operating system. 1. Place the ACTiSYS USB-IrDA Adapter Installation Driver disk into your computer s CD tray and close the tray. Access the CD drive using Windows Explorer if the following screen does not come up automatically.

9 2. Click on IrReady button at the center. The following screen will then be shown. 6. The default file location is the folder WINNT / ACTiSYS on the local hard drive. To specify a different destination, click on Browse and use Windows Explorer to name the location. Click Next once the appropriate location is shown. The Setup Status screen will be shown briefly as the files are installed. 3. Click on Installation Driver Software (near the top). The following screen may be shown if you are installing onto a PC with Windows XP. 4. Specify the appropriate model. For the purpose of this manual, we will proceed with the installation for the ACT-IR2000UL IrDA USB Adapter. The next screen will show the progress of the InstallShield Wizard setup, and will be followed by the Welcome to the InstallShield Wizard screen. 7. Click Continue Anyway. 5. Click Next to continue. The next screen will ask you to specify the file location. 8. As instructed by the software, plug the IrDA transceiver into the PC and click Finish to complete the setup. Found New Hardware will be shown on the task bar. 8

10 The New Hardware Wizard screen will then be shown. 11. Click Continue Anyway. The PC will begin to install the software. 9. Select Install the software automatically and click Next. The software will then search for the driver. Once the driver is located, the following screen will be shown. Once the installation is complete, the following screen will be shown: 10. In most installation a number of drivers will be shown. Select the driver that is appropriate for the device you are installing (in this case, the ACT-IR2000UL IrDA USB Adapter). If multiple drivers are shown for one device, choose the one that is on your local hard drive. The following screen may be shown if you are installing onto a PC with Windows XP. 12. Click Finish to complete the setup. Once completed, the task bar will indicate that the new hardware is installed and ready to use. The LEDs on the ACTiSYS Transceiver will blink every few seconds to indicate that the unit is functional. Be sure to remove the CD from your CD tray once the installation is complete. 9

11 3. Installing the IQ Administrator Pro Program To install the IQ Administrator Pro program, follow the instructions in the IQ Administrator Pro and PostgreSQL Database Server Installation Guide. 4. Installing the IQ Database Manager Pro Program To install the Database Manager Pro program, follow the instructions in the IQ Database Manager Pro Installation Guide. 5. Installing IQ Controller Pro Software Note: The IrDA Drivers and the Database Manager Pro Software must be installed prior to installing the IQ Controller Pro Software. See sections 3 and 4 above. 1. Place the IQ Installation CD into your computer s CD tray and close the tray. The following screen should come up automatically. 4. To install the IQ Controller Pro Software to the default destination folder, click Next. Otherwise, click the Browse button and use Windows Explorer to specify a different location for the files. Press the Next button once the appropriate destination directory is shown. 5. Click Next. 2. Select Controller Pro) and click the Install button at lower right. The following screen will be shown. The installation will then proceed to the 4-port serial adapter. 3. Click Next to continue. 6. Click Next. The Licensing agreement for the 4-Port Serial Adapter will then be shown. 10

12 7. Click Yes to accept the licensing agreement. Clicking No will terminate the installation. After Yes is chosen, the program will proceed to the selection of the destination directory for the USB port software. 8. To install the USB 4-Port Adapter software in the default folder, click next. Otherwise, click the Browse button and use Windows Explorer to specify a different location for the files. Once the appropriate destination directory is shown, press the Next button. The following screens will be shown as the installation proceeds. 9. Click Finish to continue. The system will then be updated with the new files. The following screens will be shown: 10. Click Finish to complete the installation. Close the Installer window and remove the CD from the CD drive. The PC must be restarted for the changes made during the installation to take effect. 6. Hardware 6.1 Initial Installation Once the software has been installed on the PC, the next step is the hardware installation. The IQ Controller should be located in an area with good ventilation and low levels of Radio Frequency Interference (RFI). Note: The IQ Controller is not designed for use in areas where high concentrations of Radio Frequency Interference (RFI) are present. 1. Assemble the IQ docks by connecting them in a series from left to right. While facing the label side of the dock, the first dock at left will be known as IQ Dock #1. 2. If more than one dock is to be used, install the link plates between the docks. 3. Connect the IQ Controller to the left input of IQ Dock#1 using the black cable. 4. Install a demand flow regulator on all calibration cylinders that will be installed in the system. Note: Demand Flow Regulators must be used on calibration cylinders used with the IQ System. Biosystems offers the demand flow regulators as part number Contact Biosystems Customer Service Department for further details. 5. Connect the blue ¼ gas line from IQ Dock #1 to the GASOUT port on the controller. Insert the tubing approximately ¼ into the port until a positive stop is observed. Note: If a Cannonball3 IQ Docking Station is to be used, two gas lines will be included for each IQ Dock. The shorter blue ¼ gas line is used to interconnect the IQ Docks. The longer gas line with quick disconnect nipple is used to connect 11

13 the gas outlet port on the top of the Cannonball 3 IQ Dock to the instrument. See step 10 below. Each IQ Controller includes a minimum of three gas input ports and one gas output port for calibration gases. The three standard input ports are labeled AIR, GAS 1 and GAS 2. Additional gas input ports are numbered GAS 3 GAS 11. The single output port is labeled GAS OUT. AIR is the designated fresh air input port. In the event that the atmosphere in which the IQ Controller may be contaminated, a bottle of Zero Air can be connected to the AIR input port with a demand flow regulator. GAS 1 is the primary gas input port. If multi-component calibration gas is to be used in the calibration process, it should be connected to the Gas1 input port. GAS 2 is a standard secondary gas input port. Depending on the configuration of the gas detectors that will interface with the system, the GAS 2 input port may not be necessary. In the event that the GAS 2 port is not used, simply leave it open. GAS 3 GAS 11 are also secondary gas input ports, but are not included with every IQ Controller. If a gas input port is not used, simply leave the port open. GAS OUT is the output port that will be connected to the inlet port on the first IQ Dock. If the gas line ever needs to be disconnected, press the orange ring in and gently pull the tubing out. 6. If more than one IQ Dock is to be used, use the small piece of blue tubing to connect the gas outlet port from Dock #1 to the inlet port of Dock #2. Continue connecting the outlet port from one dock to the inlet port on the next dock until the final dock is reached. 7. Install the calibration gas termination plug (short, crimped blue tube) at the outlet port on the final IQ Dock. 8. Connect the demand flow regulator(s) to the gas inlet ports on the back of the IQ Controller using a short piece of tubing. The tubing included with the IQ Controller has a white quick disconnect that will attach directly to the controller gas inlet ports. Note: The calibration gas concentrations must be entered into the software prior to 12 using the system. See section 8.2 below on Gas Mapping. 9. Install the black Termination Plug on the connection port on the right side of the last dock in the series. 10. If a Cannonball3 IQ Docking Station is to be used follow steps 10a-10d. 10a. Screw the gas tube support mast into the top of the IQ Dock. 10b. Attach the two gas tube support clips to the mast as shown. 10c. Connect the gas tube with the quick disconnect nipple into the outlet port on the top of the instrument. The quick disconnect nipple should be suspended from the mast as shown below and must be connected to the Cannonball3 during calibration. 10d. Plug the Cannonball3 IQ Dock into a standard 110V electrical outlet. 11. Connect the IQ Controller to the PC s USB port with the cord running out of the back of the IQ Controller. The PC may display several Found New Hardware messages as it locates the new hardware. Note: Biosystems strongly recommends the use of a UPS (Uninterruptible Power Supply) for the IQ Controller and desktop PC. 12. Connect the power cord from the IQ Controller to an appropriate wall outlet and turn on the Controller. The on/off switch is located on the back of the Controller. Note: All instruments must be removed from the IQ Docks prior to launching the IQ Controller Pro Software. 7. Database Manager Pro Software Overview This section will deal with initial use of the Database Manager Pro Program. This should be considered as a limited view of the system and is merely designed to show the user how

14 to enter a new user into the database and how to access the template settings from the IQ Controller Pro Software. The Database Manager Pro Reference Manual gives a more comprehensive view of the Database Manager Pro software. 7.1 Launch Database Manager Pro 1. Launch the software by clicking on the Database Manager Pro icon. The Database Manager Pro Program can also be accessed by clicking on the Start button followed by All Programs / Biosystems / IQ Pro / Database Manager Pro / Database Manager Pro. The Database Manager Pro Program will open to the login screen. 2. Enter your User ID and password. If this is the first time that the software has been run, enter Setup as the User ID and IQ as the Password. 7.2 Users To maintain data security, the IQ system requires the user to log in with a name and a password. Each user is also given a specific level of clearance ranging from General Use to Administrator. When a user modifies a template, the users name is saved to the Last Modified By file, which can be accessed through the Setup / Template / General Tab. The Database Manager Pro Reference Manual provides a full explanation of how to enter a new user into the system. 7.3 Templates The IQ Controller relies on user-defined templates to determine the specific functions to perform when a specific instrument is placed in an IQ Dock. To maximize flexibility, the IQ System allows for the programming of multiple templates. Each instrument must be assigned to a specific template. Whenever a new instrument enters the system, the Generic (No Change) template is automatically assigned to it. At initial launch, the Generic (No Change) template will be the only template available in the system. The Generic (No Change) template is set so that upon placement in the IQ Dock, instruments will be calibrated if over 30 days have passed since the last calibration. The Generic (No Change) template makes no changes to instrument settings. The Generic (No Change) template itself is not modifiable by the user. Whenever changes of any type are made to a template, the database logs the name of the user that is currently logged in. The user must acknowledge the change by clicking Yes on the Editing Templates warning screen. The main screen will then be shown At the first opening of the Database Manager, the default template will be the only template available. Templates are discussed in detail in the Database Manager Pro Reference Manual. 7.4 Using the system Once the software and hardware have been installed and the system has been properly configured, simply place the detector in one of the IQ Docks. PhD Lite must be ON when placed into the IQ Dock. 13

15 MultiVision must be ON when placed into the IQ Dock. Cannonball3 must be ON when placed into the IQ Dock and the gas tube with quick disconnect nipple must be connected from the outlet port on the top of the IQ Dock to the inlet port on the instrument. PhD5 must be OFF when placed into the IQ Dock. PhD Ultra must be OFF when placed into the IQ Dock. See section below for special instructions concerning the PhD5 and PhD Ultra. Note: If an alkaline version of an instrument is used in the IQ Docking Station, remove the instrument from the dock immediately after the calibration or download is complete. Leaving the unit in the dock will result in dead batteries. The system will upload the information contained in the detector s data file and perform the functions that are dictated by the template to which the detector has been assigned PhD5 and PhD Ultra Special Operating Instructions CAUTION Do not remove the PhD5 or PhD Ultra from the IQ System docking station while it is communicating with the controller. Removal of the PhD5 or the PhD Ultra from the IQ Dock while the instrument is in communication with the IQ Controller may cause the PhD5 to fail to respond to the MODE button. If the yellow Processing light on the front of the dock is lit, communication is in process do not remove the instrument. If an instrument is removed during communications and it fails to respond to pressing the MODE button, the instrument s LCD screen will display: PC Communications Sending Data To reset the instrument, remove the battery pack for 5 seconds. Once the battery pack is reinserted, the instrument will turn itself back on. Allow the instrument to complete the start-up sequence. Then turn the instrument off and return the it to the IQ Dock to resume processing IQ Dock Status LEDs Each IQ Dock has 5 or 6 LEDs (Light Emitting Diodes) located across the front of the dock that are used to indicate dock status. IQ Docks with the ability to charge rechargeable detectors include an LED that indicates charging status. Power indicates that the dock is functioning normally. Charging (optional) indicates that the instrument in the dock is currently charging. When an alkaline detector is placed in a charging-version IQ Dock, the charging LED will not be lit. Detected indicates that the dock has detected an instrument. The detected LED typically turns off after instrument processing begins. Processing indicates that the controller is in contact with the instrument in the dock and is exchanging information with it. It can also indicate that the instrument is being calibrated. Ready indicates that processing is complete and that the instrument can be removed from the dock. Fault indicates that a system error has occurred Controller Use The IQ System is designed to automate calibration and maintenance. As discussed above, the system templates control the interaction of the controller and the gas detector through the IQ Docks Calibrate now In the event that a calibration needs to be performed immediately and the calibration of the specific instrument is not due, first place the instrument in the IQ Dock and then access the IQ Controller Pro Software by clicking on the Start button followed by Program Files / Biosystems / IQ / IQ Controller. Click on the Calibrate Now button to initiate the calibration. 8. Software Configuration The IQ Controller Pro Software must be configured for the specifics of your gas 14

16 detection program prior to using the system. Sections cover the software options in detail. 8.1 Software Launch 1. Launch the Controller Software by accessing it from the Start button followed by Program Files / Biosystems / IQ Pro / IQ Controller Pro / IQ Controller Pro. processes the new controller. If this is the first launch of the software, or if there are no enabled gas ports, the software will automatically direct you to the Gas Manager. The Gas Manager is discussed below in section The software will then verify that the computer s date and time settings are correct. Click on Check Gas Setup Now to continue. The IQ Gas Manager screen will be shown. 3. Press Continue to verify the system time. Another message screen will be shown with the recommendation that all instruments be removed from the Docks during Startup. 4. Press Continue. The following screen will be shown as the system verifies that the Controller and Docks are installed and functioning correctly. Note: At least one Gas Port must be configured and set to active in IQ Gas Mapping to continue to the IQ Controller settings. 8.2 Gas Manager Calibration gases and air are drawn in through the inlet ports on the back of the IQ Controller. Each physical gas inlet port (at the back of the controller) is numbered and corresponds to one of the numbered ports listed in the Gas Manager screen. To ensure accurate calibration, the specifications for each gas source must be correctly entered in the Gas Manager under the appropriate port. Once the controller is recognized, the system will move on to a leak test. Failure to pass the leak test will result in a retest prompt. Once the leak test has been passed, the system will recognize the new controller. Two screens will be shown as the system 15 Note: The IQ Controller may be configured to calibrate Biosystems gas detectors containing O 2, LEL, CO, H 2 S, SO 2 and NH 3 sensors only. When Gas Manager is opened for the first time, none of the gas ports will be configured or enabled.

17 AIR is automatically set to Fresh Air (Ambient), meaning that the instrument will draw fresh air from the area surrounding the controller. If there is a risk that the air in the immediate surroundings is contaminated, then a bottled source of fresh air (containing 20.9% O 2, 0 PPM toxic gas and 0% LEL) should be used. Click on Fresh Air (Ambient) to access the setting. response for either propane or pentane. A discussion of equivalent calibration gases is given on the Biosystems website at under Applications Note AN Once the gas is selected, the calibration cylinder s lot number may be entered by typing it into the input box under Lot Number. If a bottled air source is required, select from Fresh Air (Supplied) or Biosystems P/N (Zero Air). If a bottled air source is specified, the lot number, installation date and expiration date can be entered in the two columns to the right. Once the lot number has been entered, click on the input box below installation to enter the cylinder installation date. The default date will be the current date in the PC. Once the input box is selected, the Select Date window will be shown. Once the fresh air source has been specified, click on the next gas port to be configured. A pull down list will open up that shows the part numbers of all Biosystems calibration gas cylinders and all custom gas mixtures that have been entered into the system. Instructions for entering custom gas mixtures are given below in section Click on the appropriate cylinder part number to select it. In this example, Gas Port 1 is configured for Biosystems most common multi-gas mixture, part number E, which contains 50% LEL (Propane Equivalent), 50 PPM CO and 50 PPM H2S. Either accept the current date or enter a new date by selecting the month and year and clicking on the day. Press Select to enter the date. The cylinder expiration date may be set in the same manner. The expiration date entered should be the one given on the gas cylinder. Once the gas cylinder has been selected and the information has been entered, the box below Enable will blink. Click on the enable box to enable the cylinder. Biosystems Equivalent Calibration gases use methane in amounts that mimic typical sensor 16

18 Enabled cylinders will show an X in the box below Enable. Continue to enter the gas cylinders until they have all been entered into the system. Once all cylinders have been entered, select File / Exit to exit from the Gas Manager. If you attempt to exit the Gas Manager without enabling a Gas Port, the system will show the following message. Defined gas mixtures will be listed in the white space at the center. The space will appear blank if no custom gas mixtures have been defined. To define a new custom gas mixture, click on the Add button at the lower left. The following screen will be shown. Press OK to return to the Gas Manager Backup Cylinders Many users choose to install backup cylinders of calibration gas so that when one cylinder is empty, instrument testing can continue without interruption. Once a cylinder is emptied, the IQ Controller automatically searches the current gas ports for a mixture of the same type. If a mixture of the same type is found, the IQ Controller will automatically begin using the new cylinder and will inform the user that there is an empty cylinder Custom Gas Mixtures To define a Custom Gas Mixture, select Custom Gases from the File Menu. Some custom gas configurations are not allowed in the system. These include: 1. Mixtures including both H2S and SO2 will not be accepted. 2. A mixture of NH3 with any other gas will not be accepted. Example: Configure custom calibration gas for a single cylinder containing 18.3% Oxygen, 40% LEL pentane calibration gas, 52 PPM CO and 12.0 PPM SO2. 1. Click on the check box next to Oxygen (O2). Then change the amount to 18.3%. The selection will then be shown under Custom Gas Contents. The following screen will be shown. 2. Click on the check box next to Combustible Gas (LEL) and change the amount to 40%. 17

19 7. Name the custom gas mixture and press Close. 3. Click on Select Gas Type and choose Pentane. The name that was given to the Custom Calibration Gas will then be shown in the list. Pentane will then be shown in the Gas Type box. LEL and the percentage will then be shown under Custom Gas Contents. 8. Press Close to exit the Gas Manager. Once a custom mixture has been defined, it will appear at the bottom of the pull down list for each Gas Inlet Port. 4. Click on the check box next to Carbon Monoxide (CO) and change the amount to 52 PPM. The selection will then be shown under Custom Gas Contents. 5. Click on the check box next to Sulfur Dioxide (SO2) and change the amount to 12.0 PPM. The selection will then be shown under Custom Gas Contents. 6. Once the mixture has been correctly entered, press the Save button at the lower right. The software will prompt you to name the new mixture. 8.3 Calibration Interval (Days) The calibration interval controls calibration frequency. When an instrument is placed in an IQ Dock, the IQ software automatically determines when the last calibration took place. Setting the calibration interval to 0 days will cause any instrument that is placed in the IQ Dock to be immediately calibrated. Setting the calibration interval to 1 day will cause any instrument that is placed in the IQ Dock to be calibrated if more than 24 hours have passed since the last calibration. Setting the calibration interval to any number greater than 1 day will cause any instrument that is 18

20 placed in the IQ Dock to be calibrated if more than that number of days have passed since the last calibration. In this case, if 2 days (or 48 hours) have passed since the last calibration, the instrument will be calibrated. 8.4 Fault Notification The Fault Notification setting determines whether the PC will notify you when the IQ System has recognized a fault with an instrument in one of the IQ Docks. A fault condition can occur for a number of reasons including calibration failure and database errors. begin instrument calibration. Then select the hour. In the example below, we ve selected 6:00 PM. To receive notification, check the box as shown below. Note: The IQ System can also be programmed to send an to a select list of recipients following the recognition of a fault. See the IQ Database Manager Pro reference manual for further details on the function. 8.5 Schedule Processing The Schedule Processing feature allows you to specify a time when instrument processing will take place. This allows the user to schedule calibration for a time when all instruments are in the IQ docks, but does not rely on anyone to actually initiate the process. Once the hour to begin processing has been selected, it will be shown in the box under Select Time. To schedule processing click on the Schedule Processing checkbox. The Select Processing Rules screen will then be shown. Click Select to accept the new setting and to return to the Calibration Gas Configuration screen. The new processing time will then appear below IQ Controller Configuration. Scheduled Processing will be checked. Click on the time indicator below Select Time to choose the hour that the IQ Controller will 8.6 Zero Purge Time The Zero Purge Time figure specifies how long the instrument will flush the system with fresh air between calibrations. 19

21 In the event that a bottled source of fresh air is connected to the AIR gas input port, this source will be used to purge the system. At the rate of 1.0 liters/minute, the system will use 1.25 liters of the bottled fresh air during a 75 second purge. 8.7 Exiting the Gas Configuration screen. Once all appropriate adjustments have been made, click Exit to close the IQ Controller Pro Software. 9. System Changes 9.1 Upgrading IQ Controller Pro Software 1. Go into the Windows Control Panel and select add / remove programs. Uninstall the Biosystems IQ Controller program. 2. Install the latest Database Manager Pro program included on the CD-ROM. 3. Restart the PC. 4. Run DbManager.exe from the Biosystems\IQ directory (Or click the Database Manager Pro link on your desktop) The program will prompt you to update your existing database. Acknowledge and update. 5. Exit Database Manager Pro. 6. Install the IQ Controller Pro Software program from the CD-ROM 7. When the controller install program prompts you regarding the "Keyspan" setup, choose "Repair" (Choices are Remove / Repair / Modify) and follow the subsequent prompts. 8. Reconnect the USB cable and restart the PC. 9. Run the Controller program from the Biosystems\IQ directory. 9.2 Adding or removing an IQ Dock To add or remove an IQ Dock from the system after the initial set up: 1. Close out the IQ Controller and Database Manager Pro software. 2. Turn the IQ Controller off. 3. Add or remove the IQ Dock. Each IQ Dock has a built-in EE-Prom that lets it identify itself to the IQ Controller and the PC, so the order of the docks is not important. 4. Turn the IQ Controller back on. 5. Launch the IQ Controller Pro Software. 9.3 Addition of Solenoid Blocks Each IQ Controller includes a minimum of one solenoid block, which can control up to three different gas sources. In the event that additional gas sources are needed, a second solenoid block may be added by the user. The addition of the second solenoid will accommodate three additional gas sources. Installation instructions are included when the second solenoid block is purchased separately. Installation of the third and fourth solenoid blocks can not be accomplished in the field. If the third or fourth solenoid block is required the IQ Controller must be returned to Biosystems. See section 10 below for contact details. Note: The IQ Controller can accept up to four solenoid blocks, which allows for a maximum of 12 gas sources (including the fresh air source). 10. Cleaning the IQ System Exterior surfaces of the IQ Controller and IQ Docks may be wiped down as needed with a damp cloth. Combustible gas sensors will be adversely affected by exposure to substances containing volatile silicone. Avoid cleaning the IQ Controller and the IQ Docks with any silicone-based products. For a list of known combustible sensor poisons see Biosystems Standard Warranty at the end of this manual. 11. Contacting Biosystems Biosystems address, phone and fax numbers are located on the front cover of this manual. In the event that a Biosystems product needs to be returned to the factory, please call Biosystems Technical Service Department to obtain a Return Authorization number (RA#). 20

22 Calibration Frequency One of the most common questions that we are asked at Biosystems is: How often should I calibrate my gas detector? Sensor Reliability and Accuracy Today s sensors are designed to provide years of reliable service. In fact, many sensors are designed so that with normal use they will only lose 5% of their sensitivity per year or 10% over a two-year period. Given this, it should be possible to use a sensor for up to two full years without any significant loss of sensitivity. Verification of Accuracy With so many reasons why a sensor can lose sensitivity and given the fact that dependable sensors can be key to survival in a hazardous environment, frequent verification of sensor performance is paramount. There is only one sure way to verify that a sensor can respond to the gas for which it is designed. That is to expose it to a known concentration of target gas and compare the reading with the concentration of the gas. This is referred to as a bump test. This test is very simple and takes only a few seconds to accomplish. The safest course of action is to do a bump test prior to each day s use. It is not necessary to make a calibration adjustment if the readings fall between 90%* and 120% of the expected value. As an example, if a CO sensor is checked using a gas concentration of 50 PPM it is not necessary to perform a calibration unless the readings are either below 45 PPM or above 60 PPM. *The Canadian Standards Association (CSA) requires the instrument to undergo calibration when the displayed value during a bump test fails to fall between 100% and 120% of the expected value for the gas. Lengthening the Intervals between Verification of Accuracy We are often asked whether there are any circumstances in which the period between accuracy checks may be lengthened. Biosystems is not the only manufacturer to be asked this question! One of the professional organizations to which Biosystems belongs is the Industrial Safety Equipment Association (ISEA). The Instrument Products group of this organization has been very active in developing a protocol to clarify the minimum conditions under which the interval between accuracy checks may be lengthened. A number of leading gas detection equipment manufacturers have participated in the development of the ISEA guidelines concerning calibration frequency. Biosystems procedures closely follow these guidelines. If your operating procedures do not permit daily checking of the sensors, Biosystems recommends the following procedure to establish a safe and prudent accuracy check schedule for your Biosystems instruments: 1. During a period of initial use of at least 10 days in the intended atmosphere, check the sensor response daily to be sure there is nothing in the atmosphere that is poisoning the sensor(s). The period of initial use must be of sufficient duration to ensure that the sensors are exposed to all conditions that might have an adverse effect on the sensors. 2. If these tests demonstrate that it is not necessary to make adjustments, the time between checks may be lengthened. The interval between accuracy checking should not exceed 30 days. 3. When the interval has been extended the toxic and combustible gas sensors should be replaced immediately upon warranty expiration. This will minimize the risk of failure during the interval between sensor checks. 4. The history of the instrument response between verifications should be kept. Any conditions, incidents, experiences, or exposure to contaminants that might have an adverse effect on the calibration state of the sensors should trigger immediate re-verification of accuracy before further use. 5. Any changes in the environment in which the instrument is being used, or changes in the work that is being performed, should trigger a resumption of daily checking. 6. If there is any doubt at any time as to the accuracy of the sensors, verify the accuracy of the sensors by exposing them to known concentration test gas before further use. Gas detectors used for the detection of oxygen deficiencies, flammable gases and vapors, or toxic contaminants must be maintained and operated properly to do the job they were designed to do. Always follow the guidelines provided by the manufacturer for any gas detection equipment you use! If there is any doubt regarding your gas detector's accuracy, do an accuracy check! All it takes is a few moments to verify whether or not your instruments are safe to use. One Button Auto Calibration While it is only necessary to do a bump test to ensure that the sensors are working properly, all current Biosystems gas detectors offer a one button auto calibration feature. This feature allows you to calibrate a Biosystems gas detector in about the same time as it takes to complete a bump test. The use of automatic bump test and calibration stations can further simplify the tasks, while automatically maintaining records. Don't take a chance with your life. Verify accuracy frequently! Please read also Biosystems application note: AN Use of equivalent calibration gas mixtures. This application note provides procedures to ensure safe calibration of LEL sensors that are subject to silicone poisoning. Biosystems website is located at 21

23 Biosystems Standard Warranty Gas Detection Products General Biosystems, LLC (hereafter Biosystems) warrants gas detectors, sensors and accessories manufactured and sold by Biosystems, to be free from defects in materials and workmanship for the periods listed in the tables below. Damages to any Biosystems products that result from abuse, alteration, power fluctuations including surges and lightning strikes, incorrect voltage settings, incorrect batteries, or repair procedures not made in accordance with the Instrument s Reference Manual are not covered by the Biosystems standard warranty. The obligation of Biosystems under this warranty is limited to the repair or replacement of components deemed by the Biosystems Instrument Service Department to have been defective under the scope of this standard warranty. To receive consideration for warranty repair or replacement procedures, products must be returned with transportation and shipping charges prepaid to Biosystems at its manufacturing location in Middletown, Connecticut, or to a Biosystems Authorized Warranty Service Center. It is necessary to obtain a return authorization number from Biosystems prior to shipment. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. BIOSYSTEMS WILL NOT BE LIABLE FOR LOSS OR DAMAGE OF ANY KIND CONNECTED TO THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY. Instrument & Accessory Warranty Periods Product(s) PhD 5, PhD Lite, PhD Plus, PhD Ultra, Cannonball3, MultiVision, Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra, ToxiVision, Ex Chek ToxiPro, MultiPro ToxiLtd Mighty-Tox Toxi3Ltd Mighty-Tox 2 Prorated credit is given towards repair or purchase of a new unit of the same type. IQ Systems, Series 3000, Airpanel, Travelpanel, ZoneGuard, Gas Chek1 and Gas Chek4 Battery packs and chargers, sampling pumps and other components, which by their design are consumed or depleted during normal operation, or which may require periodic replacement Warranty Period As long as the instrument is in service 2 years from date of purchase 2 years after activation or 2 years after the Must Be Activated By date, whichever comes first 90 days after activation or 90 days after the Must Be Activated By date, whichever comes first 3 years after activation or 3 years after the Must Be Activated By date, whichever comes first 0 6 months of use 100% credit 6 12 months of use 75% credit months of use 50% credit months of use 25% credit One year from the date of purchase One year from the date of purchase Sensor Warranty Periods Instrument(s) Sensor Type(s) Warranty Period PhD Plus, PhD Ultra, PhD 5, PhD Lite, O 2, LEL**, CO, CO+, H 2 S Cannonball3, MultiVision, MultiPro, & Duo-Tox 2 Years ToxiVision, ToxiPro, Ex Chek All Other Sensors 1 Year Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra CO, CO+, H 2 S 2 Years All Other Sensors 1 Year All Others All Sensors 1 Year ** Damage to combustible gas sensors by acute or chronic exposure to known sensor poisons such as volatile lead (aviation gasoline additive), hydride gases such as phosphine, and volatile silicone gases emitted from silicone caulks/sealants, silicone rubber molded products, laboratory glassware greases, spray lubricants, heat transfer fluids, waxes & polishing compounds (neat or spray aerosols), mold release agents for plastics injection molding operations, waterproofing formulations, vinyl & leather preservatives, and hand lotions which may contain ingredients listed as cyclomethicone, dimethicone and polymethicone (at the discretion of Biosystems Instrument Service department) void Biosystems Standard Warranty as it applies to the replacement of combustible gas sensors. 22